Method of making a polyurethane pad covering

ABSTRACT

A barrier fabric laminate for use as a coating for a gel filled article is provided. The barrier fabric laminate comprises a fluid impermeable film and a polyurethane nonwoven web which has a friction value of less than 200 g and a fabric hand of less than 200 g. The polyurethane web is formed of fibers of less than about 50 μm on average and preferably is formed with a fluorochemical melt additive by sequentially melt blowing the polyurethane web on a heated collecting drum and laminated by a nip formed by a heated nip roller and the collecting drum.

This is a division of application Ser. No. 08/490,464 filed Jun. 14,1995, now U.S. Pat. No. 5,593,769.

BACKGROUND AND FIELD OF THE INVENTION

This invention relates to the field of elastic or conformable nonwovenfabrics and laminates designed for use in low friction applications.

Gel filled supports are used in a variety of devices where the supportscan come into direct contact with a person's skin. The gel is typicallya solid tacky viscoelastic material. The solid gel typically containslow molecular weight components that can separate from the gel. As such,generally these gels should be contained in a fluid impermeable barrierlayer. This barrier layer should also be soft and conformable andpreferably has a very low friction surface, is soil resistant, has highabrasion resistance and adequate tear and puncture resistance. Incopending application Ser. No. 08/253,510, filed on Jun. 3, 1994 thereis proposed for a gel-filled wrist support, the use of a polyurethanefilm as a barrier layer. The barrier film covered gel can then furtherbe wrapped in an outer layer for comfortable contact with the person'swrists. For this outer layer there is proposed a polyurethane non-woven,leather, vinyl, "Dacron" or "Ultrilure". These outer layer materials arewrapped around the barrier film gel pad. Although this is advantageousin many respects, there is a considerable need for a barrier outer layermaterial with greater strength, soil resistance, abrasion resistance,lower friction and ease of use.

Elastomeric polyurethanes have been proposed in other uses which mayrequire skin contact. In U.S. Pat. No. 4,660,228 a glove is formed bytwo elastic sheet materials that are simultaneously die cut and heatsealed along the periphery to form the glove. One of the glove layers isan elastic polyurethane nonwoven fabric formed by a melt-spinning ormelt blowing process. In U.S. Pat. No. 4,777,080 a low abrasionresistant elastic sheet such as a melt blown ethylene vinyl acetatenonwoven is joined to a high abrasion resistant sheet such as a meltblown polyetherurethane nonwoven as the outer layer forming a highabrasion resistant laminate. The higher abrasion resistant sheetlaminate is apparently designed for use in apparel applications such asdiapers or mattress pads. U.S. Pat. No. 4,565,736 describes a surgicalcompress with a fibrous polyurethane cover layer and an absorbent layer.U.S. Pat. No. 4,414,970 describes an elastic film, such as apolyurethane film, inner layer covered by two nonwoven fabric layers.U.S. Pat. No. 5,230,701 describes a nonwoven elastomeric web for use ina wound dressing or adhesive bandage. The adhesive bandage backing layeris an elastomeric polyurethane microfiber web.

SUMMARY OF THE INVENTION

The invention is directed to a laminate for use as a barrier layercovering for a gel filled support article or the like. The laminatecomprises a microfibrous elastic polyurethane nonwoven web laminated toa fluid impervious film barrier layer. The elastic polyurethane web ispreferably joined to the film layer while in an untensioned state in aheated calendering nip such that substantially the entire polyurethaneweb is partially consolidated and laminated to the film layer. To ensureproper lamination the polyurethane web and the film layer should be heatsealable to each other, however a third heat sealable adhesion layercould also be used.

The elastic polyurethane nonwoven layer is formed of an elastomericpolyurethane which is in the form of a nonwoven elastic web ofelastomeric polyurethane fibers. The individual polyurethane fibers havean average fiber diameter of less than about 50 microns, which fibersare preferably formed by a melt blowing process. The basis weight of thenonwoven elastic web is generally about 20 to 1000 g/m², preferably 70to 150 g/m². The fibers of the web prior to calendering are randomlyarranged and generally autogeneously bonded. The outer surface of theelastic web following calendering has a friction value of less than 200g, preferably less than 150 g. The outer surface of the elastic web alsohas resistance to fiber pilling and is soft to the touch.

The film barrier layer can be any film that is conformable and can beheat sealed to the polyurethane web either directly or by a suitableadhesion or bonding layer. The composite laminate of the film barrierlayer and the polyurethane nonwoven web is conformable having a fabrichand of less than 200 g, preferably less than 100 g.

A further aspect of the invention is improvement in soil resistance byuse of a fiber treatment to give oil and water repellency. Preferredfiber treatments are fluorochemical compositions that can be applied tothe fibers in the form of a spray, immersion bath or the like. A mostpreferred fluorochemical is a melt additive included in with thepolyurethane during extrusion.

The fibrous web and the barrier film of the laminate are preferablysubstantially continuously bonded by the calendering nip, however,pattern bonding is not excluded. Generally, at least 10% of the surfacearea of the laminate is bonded by the calendering nip, preferably atleast 70%. However, with pattern bonding, the unlaminated area betweenadjacent laminated areas is at most about 1 cm wide, preferably lessthan 0.5 cm wide.

The invention also is directed at a method of preparing the abovelaminate by providing a microfibrous elastic polyurethane nonwoven webinto a nip with a barrier film layer and laminating the two under heatand pressure. The nip temperature is sufficient to create a bond betweenthe nonwoven web and the film layer. This is generally at least 100° C.for the preferred polyurethane film layer. On the nonwoven web face thenip roll is generally at least about 60° C., preferably at least atleast about 65° C. The nip pressure is preferably about 0.36 kg/cm to3.57 kg/cm, preferably 0.46 kg/cm to 2.04 kg/cm.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of the process for forming the inventionlaminate.

FIG. 2 is a cross-sectional view of a gel filled body using theinvention laminate.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The nonwoven elastic polyurethane webs are preferably formed by a meltblowing process such as that described in Wente, Van A., "SuperfineThermoplastic Fibers", in Industrial Engineering Chemistry, Vol. 48,pages 1342 et seq. (1965) or in Report No. 4364 of the Naval ResearchLaboratories published May 25, 1964 entitled "Manufacture of SuperfineOrganic Fibers" by Wente, Van A. et al., except that a drilled die ispreferably used. The average fiber diameter of those melt blown fibersis generally less than 25 microns, preferably less than 10 microns. Thethermoplastic polyurethane elastomer is extruded from the die 2 as shownin FIG. 1 and preferably forms into a web 3 between the die orifice andthe collection surface by autogenious bonding of the fibers.

In FIG. 1, a preferred arrangement is shown where the fibrous melt blownweb is collected on a smooth drum 5 and on that collection drumsubsequently laminated to a barrier film 7 by a nip 4 created by asecond heated roller 6. Alternatively, in a second embodiment, thefibrous polyurethane web could be formed in a prior process, collectedand then unrolled and brought into contact with a barrier film in aheated nip. In this second embodiment the polyurethane web could bepreheated.

The polyurethane nonwoven web is elastic such that when stretched by atleast about 25 percent and more it will recover at least 40 percent andpreferably at least 60 percent, most preferably at least 85 percent,when the elongation force is removed. The elastic web preferably has anelongation at break of at least about 250 percent, more preferably atleast 400 percent. Preferred nonwoven polyurethanes include thosedisclosed in U.S. Pat. No. 4,777,080, the substance of which isincorporated by reference.

The barrier film to which the polyurethane elastic nonwoven web islaminated is also preferably elastic, as defined above for the elasticnonwoven web. However, the barrier film can be nonelastic (i.e., recoverby less than 40 percent when stretched by 25 percent or more) butextensible as long as the laminate is elastic as is defined above andthe laminate elongation to break of at least about 100 percent,preferably at least 150 percent.

The barrier film can be any film that can be heat sealed to thepolyurethane nonwoven web either directly or by a suitably selectedintermediary layer. The barrier film must also provide fluid holdoutwith respect to the gel or the gel components and also, preferably,prevent liquid migration into the gel. A thermoplastic film is preferredwith a polyurethane film being most preferred in terms of its inertbehavior to the preferred gels, its elastomeric properties and its heatsealability to the polyurethane nonwoven web. The barrier film isgenerally about 0.018 to 0.5 mm thick, preferably 0.02 to 0.05 mm. Thebarrier film can be a single layer film or multi-layer film or a filmcoated laminate, e.g., to another nonwoven other than the polyurethanenonwoven. In the case of a multi-layer film, the individual layers canbe identical or different polymers. The outer layer of a multi-layerfilm is preferably heat sealable to the polyurethane nonwoven web.

The gel can be any stable viscoelastic material such as the elastomericblock copolymer gels described in U.S. Pat. No. 3,676,387, the substanceof which is incorporated herein by reference, or U.K. Patent No.1,268,431. These gels comprise synthetic block copolymer elastomerstackified by an oil in a ratio of about 4:1 to 15:1 oil to blockcopolymer. The block copolymers could be Kraton™ or like elastomericmaterials which are formed by alternating blocks of a polyalkenylaromatic, such as polystyrene, and a polyalkadiene such as polyisoprene,polybutadiene or hydrogenated versions thereof.

The polyurethane nonwoven web preferably is treated with afluorochemical compound to increase oil and water repellency. Preferredfluorochemicals for use as a polymer melt additive are thefluorochemical oxazolidinones, such as those disclosed in U.S. Pat. No.5,022,052 the substance of which is incorporated herein by reference.The polyurethane can contain from 0.25 to 3.0 weight percent, preferably0.75 to 1.25 weight percent of a fluorochemical, such as theoxazolidinones, as a melt additive.

The polyurethane nonwoven web is generally joined to the barrier layerin the nip at a temperature of from about 60° C. to 200° C. and apressure of about 0.36 kg/cm to 3.57 kg/cm. One or both nip rolls can beheated, preferably the roll 5 in contact with the polyurethane nonwovenis smooth and heated to a temperature of from 60° C. to 150° C. when afluorochemical melt additive is included in the polyurethane fiber. Ifthis roll is a collector roll for the polyurethane as a melt blown web,as in the preferred embodiment shown in FIG. 1, heating the rollprovides superior abrasion resistance for the laminate when afluorochemical melt additive is included in the fiber.

The surface of the nip roll in contact with the polyurethane web isgenerally both smooth and continuous, however, it can have lands andvalleys where pattern bonding is contemplated, however in this case, thelands preferably contact at least 10% of the web.

The roll 6 in contact with the film barrier layer is also preferablysmooth such as a steel roll. The temperature in the nip should be suchthat the polyurethane fibers are not fused into a film so that the webretains its open fibrous structure allowing for a limited amount of heatand/or moisture transport through the fibrous web structure.

Where a heat bonding or adhesive layer is used between the polyurethanenonwoven web and the barrier film layer, this can be a separate film,nonwoven layer or coating. If a film or nonwoven bonding layer is usedthis would be brought in between the polyurethane nonwoven web and thebarrier film layer by conventional means. A coating can be applied byspray coating, knife coating, gravure, Meyer bar or the like as acontinuous or intermittent pattern, applied to either the polyurethanenonwoven and/or the barrier film layer.

The gel filled article can be formed by any conventional means. As shownin FIG. 2 a mass of gel 19 is surrounded by an invention laminate 18 ofthe outer polyurethane nonwoven web 13 and the film barrier layer 17.This could be formed by creating a elongated tube 10 of the laminatewith a longitudinal seam 12 and two end seams (not shown). The tubecould surround a previously formed mass of gel or the gel could beinjected into the tube at one of the seams prior to the seam beingfinally sealed. The laminate could also be formed over a rigid base andsealed to the base along a peripheral edge thereof. The base could thenbe provided with suitable access holes for injection of a gel or the gelpreviously associated with the base. The gel height over the base is atleast 0.3 cm, preferably at least 0.75 cm. The gel filled articles couldbe used as pads for use in beds, wheel chairs, bike seats, or preferablywrist rests for placement in front of a keyboard or mouse. The padprovides a smooth, comformable surface which supports the wrist andallows the hands to move in a generally circular area with diameter ofabout 1 cm, preferably at least 3.0 cm, without sliding the wrist andalso permits easy movement across the pad by virtue of its low frictionvalue. The pad could be formed into any suitable shape by use ofsuitably formed laminate in conjunction with rigid supports as needed.

EXAMPLES

Abrasion Resistance

The abrasion resistance of the laminated webs of the invention wasevaluated using a Taber Abrasion Tester (available from TaberIndustries, North Tonawanda, N.Y.) and a modified test procedure. Testsamples were mounted on the standard S-36 Specimen Mounting Card andexposed to 100 wear cycles using CS-0 wheels and a 250 g load. Theabrasion resistance of the sample was subjectively evaluated by notingthe degree of "pilling" and "roping" of the melt blown (BMF) web as wellas the degree of delamination of the BMF web from the polyurethane film.

Fabric Hand

Fabric hand was evaluated using a Model 211-300 Handle-O-Meter(available from Thwing-Albert Instrument Co., Philadelphia, Pa.)following the manufacturer's suggested procedure and a 0.64 cm gapsetting. The data is reported as an average of four data points, two inthe machine direction and two in the cross machine direction. Hand datafor fabrics similar to those used on commercially available wrist rests(e.g., textured vinyl, woven polyester (PET) fabric, and a suede-likefabric) are also reported for comparative purposes.

Friction Value

The "friction value" of the laminated webs of the invention as well asthat of unlaminated BMF webs and covering materials similar to thoseused on competitive wrist rests was evaluated using a IMAAS Slip/PeelTester (available from Instruments, Inc., Dayton, Ohio). Friction valuesof the various materials against the rubber coated sled were determinedusing the test apparatus and procedures described by the equipmentmanufacturer with the sample holder traversing beneath the sled at arate of approximately 229 cm/min. The average force in grams wasdetermined for the first two seconds of travel. Fabric samples weretested in both the machine and cross machine directions. Friction valuesof fabrics similar to those used on commercially available wrist rests(e.g., textured vinyl, woven polyester fabric, and a suede-like fabric)are also reported for comparative purposes.

Tensile Strength

Tensile strengths were determined using test specimens 2.54 cm in widthand 8.9 cm in length and a Chatillion Tensile Tester (available fromChatillion, John & Sons, Inc., Greensboro, N.C.) which was operated witha jaw gap of 5.1 cm and a cross-head speed of 25.4 cm/min.

Blown Microfiber (BMF) Web Preparation

Elastomeric, nonwoven, melt blown microfiber webs were prepared using athermoplastic elastomeric polyurethane (PS440-200, a polyesterurethane,available from Morton International, Inc., Seabrook, N.H.) using aprocess similar to that described in Wente, Van A., "SuperfineThermoplastic Fibers" in Industrial and Engineering Chemistry, Vol. 48,pages 1342 et seq. (1965) or in Report No. 4364 of the Naval ResearchLaboratories, published May 25, 1964 entitles "Manufacture of SuperfineOrganic Fibers" by Wente, Van. A., Boone, C. D., and Fluharty, E. L.except that the melt blowing die had smooth surface circular orifices0.38 mm in diameter with an L/D ratio of 6.8 and a spacing of 10 holesper cm. The die temperature was maintained at approximately 225° C.±3°C., the primary air temperature and pressure were 225° C. and 35 KParespectively and the air knives were positioned with a 0.76 mm gap and a0.25 mm setback. The extruder was operated at 225° C. and the polymerthroughput rate was 134 g/hr/cm die length. The collector drum, whichwas positioned approximately 12.5-15.2 cm from the die tip, was an oilheated smooth steel drum for allowing temperature control of thecollector surface. The collector drum, when not heated by the oil,generally was about 55° C. (unheated) under normal operating conditions.Pigment (#0035067, a custom gray pigment available from ReedSpectrum,Holden, Mass. in pellet form as a concentrate in a polyurethane carrier)was manually blended with PS440-200 resin pellets to achieve a final 6weight percent pigment level before introducing the pellets into theextruder hopper. Similarly, solid flakes of the fluorochemical meltadditive were ground to a powder and manually blended with the hot, dryPS440-200 resin pellets (also including the pigment concentrate pellets)at the indicated levels prior to the pellets being introduced into theextruder hopper.

Lamination Procedure

A polyurethane film (Dureflex #PS8010, a 0.025 mm polyesterurethane typefilm, available from Deerfield Urethane, Chicago, Ill.) was laminated tothe rough, air interface surface (i.e., the non-collector surface) ofpolyurethane BMF webs prepared as described above by means of a heatednip roll positioned approximately 38 cm downstream from the point wheremicrofibers impinged on the collector drum. Lamination pressure wasvaried by adjusting the gap between the nip roller and the collectordrum. The nip roll was also connected to an oil heater to affordelevated temperature control for the lamination process.

Webs A-C

A series of BMF webs were prepared using the general BMF preparationprocedure described above except that the fluorochemical (FC)oxazolidinone melt additive similar to those described in U.S. Pat. No.5,025,052 (Crater et al.) Example 1, except that the alcohol andisocyanate reactants used to prepare the oxazolidinone were C₈ F₁₇ SO₂N(CH₃)CH₂ CH(CH₂ Cl)OH and OCNC₁₈ H₃₇, respectively. The fluorocarbonmelt additive level was varied between 0.5 and 1.0 weight percent andthe collector temperature was varied as noted in Table 1. The BMF webshad basis weights of 110 g/m² ±5 g/m². Abrasion resistance data forthese webs is reported in Table 3.

                  TABLE 1                                                         ______________________________________                                        BMF Web Preparation                                                                                  Collector                                              Web          FC (Wt. %)                                                                              Temp. (°C.)                                     ______________________________________                                        A            0.5       Unheated                                               B            1.0       77                                                     C            1.0       99                                                     ______________________________________                                    

Examples 1-6

BMF/polyurethane film laminates were prepared using the general BMF webpreparation procedure and lamination procedures described above. BMFwebs used in the laminates, which had basis weights of 110 g/m² ±5 g/m²,had fluorochemical oxazolidinone melt additive levels of 0.5 and 1.0weight percent, as noted in Table 2. Additionally, the collectortemperature was varied, as noted in Table 2. Lamination conditionsutilized in the preparation of the BMF/polyurethane film laminates arealso noted in Table 2. Abrasion resistance, friction value, and handdata for these webs are reported in Table 3. The tensile strength datafor an unlaminated sample of a polyesterurethane BMF web without the FCprocessing aid and the pigment used in the BMF web components of thelaminates of the present invention, the polyurethane film used in thelaminates of the invention, and the laminate of Example 4 are includedin Table 3 for both the machine direction (MD) and cross direction (CD).

                  TABLE 2                                                         ______________________________________                                        BMF/Polyurethane Film Laminates                                                                Collector  Nip Roll                                                                              Nip Roll                                  Example #                                                                            FC (wt. %)                                                                              Temp. (°C.)                                                                       Temp. (°C.)                                                                    Press. (kg/cm)                            ______________________________________                                        1      0.5       Unheated   116     2.09                                      2      1.0       Unehated   110     1.86                                      3      1.0       Unheated   116     2.09                                      4      1.0       71         110     0.52                                      5      1.0       77-81       99     0.23                                      6      1.0       93          99     --                                        ______________________________________                                    

                  TABLE 3                                                         ______________________________________                                        Abrasion Resistance Properties                                                Web/Example            Friction      Tensile                                  #        Abrasion Resistance                                                                         value   Hand  Strength                                 ______________________________________                                        A        Poor, significant                                                                           --      --    --                                                roping of the BMF                                                             web                                                                  B        Good, minor roping of                                                                       --      --    --                                                BMF the web                                                          C        Good, minor roping of                                                                       --      --    --                                                BMF the web                                                          1        Poor, significant                                                                           --      --    --                                                roping of the BMF                                                             web                                                                  2        Poor, significant                                                                           --      --    --                                                roping of the BMF                                                             web                                                                  3        Poor, significant                                                                           --      --    --                                                roping of the BMF                                                             web                                                                  4        Best, minor roping of                                                                       134 g   65.2 g                                                                              59.85 N-MD                                        the BMF web                 36.67 N-CD                               5        Poor, minor roping but                                                                      --      --    --                                                extensive delamination                                                        of the BMF web from                                                           film                                                                 6        Poor, minor roping but                                                                      --      --    --                                                extensive delamination                                                        of the BMF web from                                                           film                                                                 PET Fabric.sup.1                                                                       --            175.2 g 35.5  --                                       Suede-Like                                                                             --            233.5 g 185.5 g                                                                             --                                       Fabric.sup.2                                                                  Vinyl Fabric.sup.3                                                                     --            117.2 g >1000 g                                                                             --                                       BMF Web.sup.4                                                                          --            --      --    24.48 N-MD                                                                    20.34 N-CD                               PU Film.sup.5                                                                          --            --      --    14.02 N-MD                                                                     9.75 N-CD                               ______________________________________                                         .sup.1 A woven PET fabric similar to that used for "mouse pad" surfaces.      .sup.2 Suedelike fabric, similar to ULTRASUEDE, a fabric available from       Springs Industries, Inc., Fort Mill, SC.                                      .sup.3 Vinyl coated fabric, available as NAUGAHYDE.                           .sup.4 A 110 g/m.sup.2 basis weight web produced essentially as described     in Example A except that it did not contain the FC processing aid and the     gray pigment.                                                                 .sup.5 Dureflex PS8010 film used in the preparation of the laminates of       the invention.                                                           

The data in Tables 1-3 demonstrate that with the PS440-200polyurethane/fluorochemical oxazolidinone formulation it is necessary tohave an elevated collector temperature (greater than 70° C.) to produceBMF webs having good abrasion resistance (i.e., to minimize roping). Thedata also demonstrate that if a collector temperature less than about70° C. is used during the production of the BMF web, roping cannot besignificantly reduced by utilizing higher nip roll temperatures duringthe lamination procedure. Additionally, nip roll pressure is a verycritical aspect of the lamination procedure, as laminates produced withnip roll pressures significantly less than about 0.52 kg/cm are subjectto extensive delamination. Generally speaking, the combination of lowfriction value and favorable hand provided by the polyurethane BMF/filmlaminates of the present invention make them more preferred thanconventional fabrics as covering materials for wrist rest articles.

The oil and water repellency properties of the laminate of Example 4were demonstrated using SCOTCHGARD Textile Finishes-SP3010 Oil Test Kitand SCOTCHGARD Textile Finishes-SP3011 Aqueous Test Kit respectively(available from 3M, St. Paul, Minn.) and their associated testprocedures. Generally speaking, the oil challenges (1-8) decrease inviscosity with increasing number while the surface tension of theaqueous challenges (1-10) decrease with increasing number as theisopropyl alcohol (IPA) content of the challenge increases from a 90/10ratio for challenge 1, to a 100 percent IPA content, in 10 percentincrements, for challenge 10. Five drops of each of the oil and aqueouschallenge fluids were placed on the test specimen and the degree whicheach drop was absorbed by the BMF web after a period of 60 seconds wasnoted. None of the test drops of the oil repellency challenges 1-5 wereabsorbed by the laminate, corresponding to a oil repellency rating of 5and none of the drops of aqueous challenges 1-10 were absorbed by thelaminate, corresponding to an aqueous repellency rating of 10.

Web D and Examples 7-9

A polyurethane BMF web was prepared essentially according to the BMF webpreparation process described above except that an elastomericpolyurethane PS 79-200 from Morton International, Inc., was substitutedfor the PS440-200 resin and the extrusion temperature, the dietemperature, the primary air temperature, the primary air pressure, andthe collector temperature were adjusted in response to the lower melttemperature of the polyesterurethane resin. The BMF web had basisweights of 110 g/m² ±5 g/m² and contained 1 weight percent of thefluorochemical processing additive. Laminates of the BMF Web D to aDureflex #PS8010 polyurethane film were prepared essentially accordingto the process described for Examples 1-6 except that the collectortemperature was varied while the fluorochemical processing aidconcentration and the lamination conditions were held constant. Specificprocess details for the examples are reported in Table 4 and theabrasion resistance for the samples is reported in Table 5.

                  TABLE 4                                                         ______________________________________                                        PS79-200 BMF/Film Laminates                                                   Web/Example                                                                            Collector   Nip Roll  Nip Roll Pressure                              #        Temp. (°C.)                                                                        Temp. (°C.)                                                                      (kg/cm)                                        ______________________________________                                        D        Unheated    --        --                                             7        54          110       1.86                                           8        63          110       1.86                                           9        71          110       1.86                                           ______________________________________                                    

                  TABLE 5                                                         ______________________________________                                        Abrasion Resistance Properties                                                Web/Example                                                                   #        Abrasion Resistance                                                  ______________________________________                                        D        Poor, significant roping of the BMF web                              7        Poor, significant roping of the BMF web and significant                       delamination                                                         8        Good, some roping but no delamination                                9        Best, minor roping and no delamination                               ______________________________________                                    

The data in Tables 4 and 5 demonstrate that with thePS79-200/fluorochemical oxazolidinone formulation a collectortemperature of about 60° C. was needed to achieve good lamination of theBMF web to the polyurethane film. More preferably, the collectortemperature should be at least about 70° C. to achieve improved abrasionresistance of the BMF web film laminate. Oil and aqueous repellenciesfor the laminate of Example 8, which were determined as described forExample 4, were 5 and 10 respectively.

We claim:
 1. A method for forming a soft conformable elastic barrierfabric comprising laminating a fluid impermeable film layer and anuntensioned elastic nonwoven fibrous web containing polyurethane fibers,where the polyurethane fibers have an average diameter of less than 50μm, at a nip temperature of greater than 60° C. and a nip pressure ofgreater than 0.36 kg/cm so as to produce a laminate wherein the outerface of the polyurethane nonwoven web has a friction value of less thanabout 200 g, and the fabric hand of the laminate is less than about 200g.
 2. The method of claim 1 wherein one roll forming the nip is acollector roll the method further comprising the step of forming thenonwoven web as melt blown web on the collector roll and heating thecollector roll to at least 60° C.
 3. The method of claim 2 wherein thecollector roll has a smooth outer surface.
 4. The method of claim 3wherein the nip pressure is 0.46 kg/cm to 2.04 kg/cm.
 5. The method ofclaim 4 wherein the collector roll is at least 65° C.
 6. The method ofclaim 2 further comprising adding a fluorochemical melt additive in anamount of 0.25 to 3.0 weight percent of the polyurethane melt prior tomelt blowing the polyurethane fibers.